Method of assembling arcuate terminal banks



April 6, 1948. L. A. BAR'n-:LHEIM ETAL 2,438,959

METHOD OF ASSEMBLING ARCUATE TERMINAL BANKS Filed Dec. 12, 1942 5 Sheets-Sheet 1 @WQ mm mm l ,.IJ

April 6, 1948. l.. A. BARTELHEIM ETAL 2,438,959

METHOD OF ASSEMBLING ARCUATE TERMINAL BANKS Filednec. 12, 1942 s sheets-sheet z April 6, 1948. L. A. BARTx-:LHEIM Erm. 2,438,959

METHOD 0F ASSEMBLING ARCUATE TERMINAL BANKS Filed Dec. 12, 1942 3 sneets-sneet s Patented Apr. 6, 1948 METHOD OF ASSEMBLING ARCUATE TERMINAL BANKS Leland A. Bartelheim, Berwyn, and Maurice W.

Lane, Chicago, Ill., assignors to Western Electric Company, Incorporated, New York, N. Y.,

a corporation of New York Application December 12, 1942, Serial No. 468,808

to improvements in the manufacture of contact I bank equipment such as is used in switching mechanisms for extending connections in automatic telephone systems.

In certain types of telephone systems, automatic switching mechanisms are employed in which wipers are operated to travel along an interconnected series of banks of contacts to establish electrical connections between the wipers and Iselected contacts of the several banks. Heretofore, it has been the practice in some instances to manufacture these banks of contacts as separate and individual units, each comprising a predetermined number of individual contacts arranged in arcuate layers with separating insulators interposed between the layers. The required number of such banks of contacts were then mounted in proper relation to each other on a supporting frame, after which the corresponding contacts of the several banks were wired or interconnected by rst stripping the insulation from the connecting wires at predetermined intervals and then manually fastening and soldering the bared wire portions to the terminal portions of the contacts.

An object of the present invention is to reduce the manufacturing cost and improve the quality of Contact bank equipment of the type referred '.Ato.

' In accordance with one embodiment of `the invention, a simple and improved method of manufaeturing contact bank equipment is provided in which the contacts are formed with solderless terminal portions and are attached to separate insulating cards, after which the separate cards of the contacts are electrically connected to continuous stranded conducting wires at spaced intervals by means of the terminal portions of the contacts which are clinched to the wires and are formed with tangs which pierce through the insulation to make electrical contact with the stranded conducting wires. The thus formed continuous string of interconnected cards of contacts is then cut into predetermined lengths, each comprising a predetermined number of interconnected cards of contacts, after which the required number of these lengths or so-called levels of interconnected Contact cards are stacked and clamped together to form an interconnected series of contact banks.

In the application of the method of the present invention to the manufacture of contact bank equipment of thetype used for extending tip and ring connections in so-called step-by-step telephone systems, the tip and ring contacts are attached to separate cards which are subsequently arranged in pairs with a card of ring contacts superposed upon a card of tip contacts and a separating insulator interposed therebetween. These pairs of contact cards are then electrically connected by means of continuous conducting wires to which corresponding tip and ring contacts on successive cards are connected at spaced intervals. In order to control cross talk, the connecting wires of each pair of tip and ring contacts may be twisted together between successive pairs of cards as they are assembled into a continuous string of interconnected pairs of Contact cards. This continuous string of interconnected pairs of Vtip and ring contact cards is then cut into predetermined lengths, after which the required number of these lengths or levels are assembled into an interconnected series of tip and ring contact banks.

A more complete understanding of the above referred to application of the method of the invention will be had from the following detailed description thereof when read in conjunction with the accompanying drawings, in which Fig. 1 shows a layer of tip contacts attached to the upper side of an insulating card;

Fig. 2 shows a layer of ring contacts attached to the underside of an insulating card;

Fig. 3 shows a sub-assembly comprising a card of ring contacts superposed upon a card of tip contacts with a separating insulator interposed therebetween;

Fig. 4 illustrates schematically a preferred method of forming a string or level of interconnected tip and ring contact card sub-assemblies;

Fig. 5 is an enlarged plan view of a portion of a string or level of interconnected tip and ring contact card subassemblies, with sorne of the conducting wires omitted for clearness;

Fig, 6 is a plan view of a portion of an interconnected series of tip and ring contact banks formed by stacking and clamping together the required number of levels of interconnected tip and ring contact card sub-assemblies of the form shown in Fig. 5;

Fig. 7 is an enlarged cross sectional view taken on line 1 1 of Fig. 6, and

Fig. 8 is an enlarged cross sectional view through the terminal portion of one of the contacts.

The method illustrated in the drawings comprises the initial step of attaching a plurality What is claimed is:

LA method of making a series of interconnected contact banks, which comprises attaching a plurality of contacts to each of a plurality of insulator cards, electrically connecting correspending contacts on a series of insulator cards to continuous conducting wires at spaced intervals to form a continuous string of electrically interconnected contact cards, intertwisting the wire connecting one set of corresponding contacts with another wire connecting another set of corresponding contacts in the area between the points of connection of said wires with their associatcd contacts, cutting the thus formed string of contact cards into predetermined lengths, and then assembling a predetermined number of such lengths of interconnected contact cards into a series of interconnected contact banks.

2. A method of making a series of interconnected contact banks, which comprises attaching a plurality of contacts to each of a plurality of insulator cards, arranging the thus formed cards of contacts in pairs with the contact cards of each pair arranged one above the other, electrically connecting corresponding contacts on a series of pairs of contact cards to continuous conducting wires at spaced intervals to form a continuous string of electrically interconnected pairs of contact cards, twisting together the connecting wires of the upper contacts with the connecting wires of the associated lower contacts, cutting the thus formed string oi interconnected pairs of contact cards into predetermined lengths, and then assembling a predetermined number of said lengths of interconnected pairs of contact cards into a series of interconnected contact banks.

3. A method of making a series of interconnected contact banks which comprises connecting a plurality of pairs oi conductors to the contacts on an insulator card, intertwisting each pair of conductors in one direction, connecting said pairs or conductors to the contacts of another insulator card, intertwistlng each pair of said conductors in the opposite direction, connecting said pairs of conductors to the contacts oi another insulator card, repeating these steps to form a series of lengths oi interconnected insulator cards, and assembling a predetermined number of such lengths of interconnected cards into a series of interconnected contact banks.

tl. A method or making a length o interconnected insulator cards which comprises successively feeding insulator cards with contact terminals attached thereto to a work station, iced-- ing a plurality of converging pairs of conductors to said work station, electrically attaching said conductors to said contact terminals, intertwisting pairs of conductors as they are advanced, electrically attaching said conductors to the con'- tact terminals or" another insulator card, intertwisting said pairs of conductors in the opposite direction, and repeating these steps to iorm lengths of interconnected cards.

5, The method ci assembling arcuate terminal banks, which comprises, longitudinally advancing pairs of insulation covered wires, twisting each pair between successive local zones, electrically connecting corresponding terminals of successive individual arcuate groups to the same pairs of wires at the successive zones, and thereafter assembling the groups in banks.

6. The method oi electrically connecting arcuate groups of terminals lying in a common plane, which comprises, disposing several pairs each consisting of two elongated conductors twisted about each other so that successive local zones of each twisted pair of conductors are spaced apart, positioning the corresponding terminals of successive similar arcuate terminal groups adjacent to the same conductors at the successive spaced apart zones, and simultaneously attaching the conductors to the terminals at said zones.

7. The method of electrically connecting arcuate groups of terminals lying in a common plane, which comprises, disposing several pairs each consitting of two wires twisted about each other so ihat a predetermined number vof local zones at cach of which the twisted wires'of each pair are spaced apart are periodically produced throughout the length of the wires, positioning the corresponding terminals of successive similar arcuate terminal groups adjacent to the same wire at the successive spaced apart zones, and simultaneously attaching the wires to the terminals at said zones.

8. The method of electrically connecting arcuate groups of terminals lying in a common plane` which comprises, disposing several pairs of wires so that successive local zones of each pair are spaced apart, twisting each complementary pair of wires about each other between said spaced apart zones, positioning the corresponding terminals of successive similar arcuate terminal groups adjacent to the same wires at the successive spaced apart zones, and simultaneously connecting the terminals of each group to the adjacent wires at said zones.

9. The method of electrically connecting arcuate groups of terminals lying in a common plane, which comprises, disposing several pairs of insulated wires so that successive local zones of each pair are spaced apart, twisting each complementary pair of wires about each other on opposite sides of each of said zones, placing the corresponding terminals of successive complementary groups adjacent to the same wires at the successive zones, and simultaneously clamping the terminals to the adjacent wires to produce electrical connections through the insulation.

l0. The method or electrically connecting arcuate groups oi terminals, which comprises, longitudinally advancing a plurality of elongated conductors, oppositely twisting adjacent pairs of said conductors about each other on opposite sides o1? successive local zones, periodically positioning successive groups of terminals at the successive zones along said conductors, and thereafter electrically connecting the terminals of a series of groups to 'the adjacent conductors.

ll. The method of electrically connecting arcuate groups of terminals, which comprises, longitudinally advancing a plurality ci' wires, oppositely twisting adjacent pairs of said wires about each other on opposite sides or" successive local zones, `periodically positioning successive groups of terminals at the successive Zones along said wires, and thereafter simtdtaneously electrically connecting all of the terminals of each group to the same wires at the successive zones.

l2. The method of electrically connecting arcuate groups of terminals, which comprises, longitudinally advancing several pairs of wires, twisting each complementary pair of Wires about each other between successive zones thereof, positioning successive groups of terminals at the successive zones, and thereafter electrically connecting all of the terminals of each group to the corresponding pairs of previously twisted wires at the successive zones.

sessies@ 1S., The meth of eieetriceliy cerimectius eromete groups oi ,sfr-z which comprises, peIn riodicelly longitudinally silva-meine' several pairs of wires, twisting the wires of etch pair about each other on opposite sides of successive zones spaced equi-distance slang the wires., positioning successive similar groups of teneis et the successive zones, and thereafter simultaneously elec*a triceliy connecting all of the termimels et each group to the seme wires et tile successive zones.

le. The metlioel oi essembliug ercuete terminal banks, which comprises, longitudinally advancing pei-,rs of Wires, twisting each peli between successive zones, clempiiig correspencling sets ei ter minels of silecessiire similar individuel arcuate groups to the seme pelis of wires et the susI cessive zones, emol assembling seid groups in banks disposed laterally edjecent to each other.

l5. The method ci eltrieelly connecting suc cesslve simile? groups o tuels, which com= prises, lonsitudiiialiy advancing pairs of insulation covered wires, twisting each, ptir of Wires about each other on the oppesite sides of successive iocel zones, electrically connecting corresperidine terminals of successive simmer groups to the seme pairs of wires et the suceeste series, enel thereafter assembling the groups im stacks.

i6. The method of electrically connecting suc= cessive simileiv groups oi terminals, which somierises, longitudinally sdvsiiclne pairs o insu1xi= tion covered `Wires convert-singly toward e common locality, twisting eecle pair oi wires about each other on opposite sides of successive locati zones while proceeding. toward seid locelity, electrically connecting corresponding :p ist oi successive s sier groups to the seme pelis oi emes et seid locality, end thereafter assembling the groups im stacks.

' l'l. The method of electrically :connecting successive similar: groups of terminals, which. seme prises, longitudinally edveneing @airs of iiisiiles tion covered wires convereingly toward e. com= mon loeelity, twisting each pair ef wies shout each. otherl on opposite sides of successive local zones while proceeding toward seiol locality, enel electrically connecting corresponding terminals at successive similar pairs of terminals to the seme pairs of wires et seid locality.

i- .n- A. BARTELl-EEM. MAURCE W. LANE.

j iessselsisess etres The following references ere oi' record. in the file el this patent:

UNITED STATES PATENTS 

